Spa or Hot Tub Cover

ABSTRACT

A cover or a spa or hot tub having a shell and a foam core. The cover may be in two-pieces attached together at a hinge. The two pieces are tapered from the center towards the lateral edge. The top side may be substantially seamless. The top side may also be made of a hard plastic.

CROSS-REFERENCE TO RELATED APPLICATION

This patent application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/807,520, flied Aug. 19, 2013, entitled “Spa or hot tub cover,” which application is incorporated in its entirety here by this reference.

TECHNICAL FIELD

This invention relates to covers for spas, hot tubs, and the like.

BACKGROUND

Outdoor spas, hot tubs, and the like are usually kept covered when not in use to keep debris out and reduce evaporation of the water. The covers, being exposed to the elements of nature, suffer typical wear and tear due to sun, rain, changing temperatures, and the like. Exposure to the elements result in significant damage to the spa cover, particularly the top side.

The covers generally have a foam core covered in a vinyl shell. The vinyl shell is typically sewn together in a manner that creates seams on the top side. These seams create a weak point and are usually the first place significant damage occurs when exposed to the elements.

To improve the structural integrity of the cover and minimize sagging, others have simply increased the thickness of the cover. This, however, has not overcome the problems with the current covers.

For the foregoing reasons there is a need for a new design for spa and hot tub covers that can better withstand the elements of nature and avoid the accumulation of unwanted water pools.

SUMMARY

The cover of the present invention has a number of features that improve function and help eliminate problem areas associated with other hot tub/spa covers. One such feature pertains to the amount of taper which allows for rain to run off of the cover. The cover is generally a two-piece cover attached by a hinge. In the preferred embodiment, each piece or section is generally wedge-shaped having a taper that starts at about 5 inches in the center of the cover and tapers down to about 2 inches at the outside edge, which gives much better performance and virtually eliminates puddling which can cause the cover to sag and stress the seams causing premature cover failure.

Another feature pertains to the seams. Existing covers are generally made with vinyl and require a seam connecting the top side of the shell to the bands that make up the sides of the shell that then need to be sewn to a bottom creating a bag or encasement into which the foam core can be inserted. The present invention eliminates at least about two thirds of the top seam thereby eliminating or significantly reducing, the number of areas of seam failure. This also allows the handles to be moved to the outer corners of the cover which increases leverage while reducing handle failure due to stress and making opening and closing the cover more convenient. Further, this design offers the customer the choice of “mixing” colors to add a level of customization to their cover.

Another feature is to make the top side of the cover a hard shell by using plastic material. This may create a problem for inserting the foam core. However, this problem is solved by creating an opening that extends along one side and partially onto the two adjacent sides.

The aforementioned features can be used in any combination.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a perspective view of an embodiment of the present invention.

FIG. 2 shows an exploded view of the embodiment shown in FIG. 1.

FIG. 3A shows a perspective view of one section of the cover.

FIG. 3B shows another perspective view of the section shown in FIG. 3A.

FIG. 3C shows a front elevation view of the section in FIG. 3A.

FIG. 4 shows a cross sectional view taken along line 4-4 of FIG. 3A.

FIG. 5 shows a cross sectional view of a shell taken along line 4-4 shown in FIG. 3A.

DETAILED DESCRIPTION OF THE INVENTION

The detailed description set forth below in connection with the appended drawings is intended as a description of presently-preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.

Referring to FIGS. 1 and 2, the cover 100 of the present application comprises a first section 102 a and a second section 102 b, the first and second sections 102 a, 102 b each comprising a shell 200, and a foam core 300 housed inside the shell 200. The first section and the second sections 102 a, 102 b may be identical pieces, that when assembled together with a hinge 104, are mirror images of each other with the hinge 104 at the center. As such, only one section 102 will be described in detail, but the description is applicable to both sections 102 a, 102 b.

Referring to FIGS. 3A-3C, each section 102 has a top side 110 and a bottom side 112 opposite the top side, wherein a distance between the top side 110 and the bottom side 112 defines a height H. Each section 102 also has a lateral side 114 adjacent to the top and bottom sides 110, 112 and a medial side 116 opposite the lateral side 114, the medial side 116 adjacent to the top and bottom sides 110, 112, wherein a distance between the lateral side 114 and the medial side 116 defines as width W. Each section 102 also has a front side 118 adjacent to the top 110, bottom 112, lateral 114, and medial 116 sides, and a back side 120 opposite the front side 118, the back side 120 adjacent to the top 110, bottom 112, lateral 114, and medial 116 sides, wherein a distance between the front side 118 and the back side 120 defines as length L. A top edge 122 is defined where the top side 110 meets the front 118, back 120, lateral 114, and medial 116 sides., A bottom edge 124 is defined where the bottom side 112 meets the front 118, back 120, lateral 114, and medial 116 sides. The hinge 104 connects the first section 102 a to the second section 102 b at their respective medial sides 116. Reference to directional terms, such as top, bottom, front, back, lateral, medial, and the like are used for ease of description only, and are not meant to be limiting.

In order to reduce or eliminate the puddling, on the top side 110, each section 102 may taper from the medial side 116 to the lateral side 114. The tapering creates a wedge shape when viewed from the front or from the back as shown in FIG. 3C or in cross-section as shown in FIG. 4. Preferably, the height H1 at the medial side 116 is more than two inches higher than the height H2 at the lateral side 114. More preferably, the height differential measured at the medial side 116 compared to the lateral side 114 is three inches or more. For example, the tapering may be a linear slope in which the height H1 at the medial side 116 is about five inches and the height H2 at the lateral side 114 is about two inches.

Other suitable dimensions for height H1 and height H2 are four inches to one inch and six inches to three inches, respectively. In general, the angle of rise A from the top of the lateral side 114 to the top of the medial side 116 may be 2.5 degrees or more. In some embodiments, the angle of rise A is 2.8 degrees or more. In some embodiments, the angle of rise A may be 3.5 degrees or more. in some embodiments, the angle of rise A may be 5.7 degrees or more. For example, a section having a 60 inch width W with a height H1 at the medial side 116 of 5 inches and a height H2 at the lateral side 114 of 2 inches has an angle of rise A of about 2.86 degrees. A section having a 48 inch width W with a height H1 at the medial side 116 of 5 inches and to height H2 at the lateral side 114 of 2 inches has an angle of rise A of about 3.58 degrees. Having a steeper angle of rise A as discussed above improves the load-bearing capacity and performance of the cover 100 by about 50% compared to traditional spa covers.

Although in the preferred embodiment, the top side 110 creates a flat surface, a curved surface can also be used giving the cover 100 an overall dome-shaped appearance rather than a triangular-shaped appearance.

Each section 102 comprises a foam core 300 and a shell 200. The wedge-shaped appearance is created by cutting the foam core 300 into the proper dimensions. Therefore, the foam core 300 also has a top side, a bottom side opposite the to side, a lateral side adjacent to the top and bottom sides, a medial side opposite the lateral side and adjacent to the top and bottom sides, a front side adjacent to the top, bottom, lateral, and medial sides, and a back side opposite the front side and adjacent to the top, bottom, lateral, and medial sides to create the section described above.

The foam core 300 provides a sturdy foundation. In the preferred embodiment, as shown in FIG. 4, an EPS foam blank is cut with the taper described above and then shaped to the correct size and shape of the spa, for example, octagon, round, square, rectangle, etc. In some embodiments, at least one e-channel 202 of steel or aluminum (one channel in each half of the cover) may be inserted into the medial side 116 to give the foam core 300 support in what will become the center region of the cover 100 where the hinge 104 is connected. In some embodiments, the core 300 may be wrapped and sealed with a water-proof barrier 204 to prevent the core 300 from taking on water due to moisture vapor transmission.

Next, using a marine grade vinyl material, or some other type of suitable material, a shell 200 is created to fit the foam core 300. Therefore, as shown in FIG. 5, the shell 200 also has a top side 210, a bottom side 212 opposite the top side 210, a lateral side 214 adjacent to the top and bottom sides 210, 212, a medial side 216 opposite the lateral side 214 and adjacent to the top and bottom sides 210, 212, a front side (cut away) adjacent to the top 210, bottom 212, lateral 214, and medial 216 sides, and a back side 220 opposite the front side and adjacent to the top 210, bottom 212, lateral 214, and medial 216 sides to create the section 102 described above.

In traditional shells, the top side of the shell is a separate sheet of material than the sides or bands. The separate top side is then sewn to the front, back, medial, and lateral sides, thereby creating a seam on the top side, particularly along or adjacent to the top edge. The present invention, however, has a substantially seamless top side 210. Therefore, the top side 210 may be cut from a roll stock as one continuous sheet with at least a portion of at least one of the sides (lateral, medial, front, and/or back sides). By way of example only, the top side 210 of the shell 200 may be one continuous sheet with one side, such as the lateral side 214. In another example, the top side 210 of the shell 200 may be a single sheet that extends down towards two other sides, such as the front and back sides. In another example, the top side 210 may be a single sheet extending down all tour sides. Therefore, the top side 210 can extend down any one or more sides in any combination thereof, so as to reduce the amount of seams on the top side 210 compared to traditional covers.

Furthermore, the single sheet of the top side 210 may extend down either partially into any of the adjacent side(s) (front, back, lateral, and/or medial), or it may cover the entire adjacent side(s). Therefore, a majority of the seams that would have normally been on the top side 210 of typical covers, is moved either to the adjacent sides, to the bottom edge, or to the bottom side.

By reducing the amount of seams from the top side 210, the structural integrity of the cover 100 in general is improved. This is because most of the damage occurs on the top side 210 and tine weakest point, which tends to be the seams. By eliminating or reducing the amount of seams on the op side 210, the covers 100 can last much longer.

Another way to improve the structural integrity of the shell 200 to better withstand the elements of nature is to use a hard plastic) the top side 210. So, rather than the top side 210 being made of vinyl, the top side 210 may comprise a hard plastic, such as acrylonitrile butadiene styrene (ABS) and other similar or equivalent plastics. Suitable plastics, such as ABS plastic, do not shrink when exposed to the various elements or weather changes. Therefore, not having seams on the top side 210 is not as critical. In the preferred embodiment substantially all of the top side 210 may be made of hard plastic. The adjacent sides (front, back, lateral, and medial) and the bottom side can still be made of vinyl. The adjacent sides are then fastened to the side 210, for example, by stitching along or adjacent to the top edge 222. Like the previous embodiment, however, the plastic top side 210 may extend down to any one or more of the adjacent sides (front, back, lateral, and/or medial sides) either partially or completely making up one or more of the adjacent sides.

A problem that arises with a hard plastic top side 210 is that the lack of flexibility poses difficulty with inserting the foam core 300 into the shell 200. This problem is solved by creating an opening 215 along the medial side 216 of the shell 200 that extends into the front and back sides of the shell. The opening 215 an be opened and closed with a fastener, such as a zipper, buttons, hook-and-loop fasteners, and the like. A patch 130 may be fastened to the front and back sides to cover the fastener and improve the structural integrity at the opening to reinforce the weak point created by the opening 215.

Spa covers generally have handles along the lateral sides of the shell. In any embodiment discussed herein, the cover 100 may comprise one or more handles 126 along one of the sides (front, back, and/or lateral sides). However, with the structural integrity improved, the handles 126 can be positioned in the outer corners where the front 118 and lateral 114 sides meet and where the back 120 and lateral 114 sides meet. Having the handles 126 in the corners improves the leverage for lifting the cover 100 and reduces the stress applied to the shell 200. The handles 126 may be made of fabric material that is fastened at the outer corners of the shell 200, for example, with stitching.

Each section 102 may further comprise a second handle 128, referred to as an inner handle, along the medial side 116. The inner handle 128 can be used to move and manipulate the cover 100 when in the folded configuration with one section 102 a on top of the other section 102 b. The medial side 116 may also comprise one or more gaskets 132 a, 132 b to help create a tight seal in between the two sections 120 a, 102 b when in the open configuration. The gaskets 132 a, 132 b, may be heat sealed gaskets.

To fully assemble the cover 100, two identical or similar sections 102 a, 102 b, can be placed adjacent to each other along their respective medial sides 116. The hinge 104 is fastened along the top side 110 of each section, along the longitudinal center, to attach the two sections 102 a, 102 b in a rotatable manner such that either section can be flipped on to the other section with the top side 110 of one section 102 a abutting against the top side 110 of the other section 102 b.

Along the front side 118 and the back side 120 at the junction where the first section 102 a meets the second section 102 b, referred to as the medial junction, end caps 134 may be used to cover any gap. A skirt 140 may also be attached along the bottom edge 124 at the front 118, back 120, and lateral 114 sides to extend the coverage of the spa or hot tub upon which the cover 100 is placed. Straps (not shown) may also dangle from the front 118, back 120, and/or lateral sides 114. The straps may be used to secure the cover 100 to the spa.

Another aspect of the invention is the ability to customize or make unique pattern combinations with the handle 126, patch 130, and end caps 134. Due to the improved structural integrity of the shell 200 provided by moving a majority of the seams off of the top side 310, fabric handles 126 can be stitched to outer corners of the sections 102. The end caps 134 and patches 130 can utilize the same fabric material as the handle 126 for color coordination. Due to the ease with which these fabric handles 126, end caps 134, and patches 130 can be manufactured and attached to the sections, they can be made in a variety of patterns and/or colors. Customers may be able pick and choose from a variety of patterns and/or colors, or create their own design, to give their covers a unique appearance.

The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. It is not intended, to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention not be limited by this detailed description, but by the claims and the equivalents to the claims appended hereto. 

What is claimed is:
 1. A spa or hot tub cover, comprising a first section and a second section, the first and second sections each comprising: a. a shell having i. a top side, ii. a bottom side opposite the top side, wherein a distance between the top side and the bottom side defines a height, iii. a lateral side adjacent to the top and bottom sides, iv. a medial side opposite the lateral side, the medial side adjacent to the top and bottom sides, wherein a distance between the lateral side and the medial side defines a width, v. a front side adjacent to the top, bottom, lateral, and medial sides, vi. a back side opposite the front side, the back side adjacent to the top, bottom, lateral, and medial sides, wherein a distance between the front side and the back side defines a length, vii. a top edge defined by a junction where the top side meets the front, back, lateral, and medial sides, and viii. a bottom edge defined by a junction where the bottom side meets the front, back, lateral, and medial sides, wherein the top edge of the shell at the front, lateral, and back sides is seamless; b. a foam core housed inside the shell; c. a skirt attached to a portion of the bottom edge of the shell; d. a handle positioned at a corner; and e. a hinge connecting the first section to the second section at their respective medial sides, wherein each section tapers from the medial side towards the lateral side.
 2. The spa cover of claim 1, further comprising a c-channel attached to the medial side of at least one of the sections.
 3. The spa cover of claim 1, wherein the foam core is wrapped and sealed with a barrier.
 4. The spa cover of claim 1, further comprising a gasket attached to the medial side of at least one of the sections.
 5. The spa cover of claim 1, further comprising, an internal handle attached to the medial side of at least one of the sections.
 6. The spa cover of claim 1, wherein the height measured at the medial side is more than two inches higher than the height measured at the lateral side.
 7. A spa cover, comprising a first section and a second section, the first and second sections each comprising: a. a shell having i. a top side comprising a hard plastic, ii. a bottom side opposite the top side, wherein a distance between the top side and the bottom side defines a height, iii. a lateral site adjacent to the top and bottom sides, iv. a medial side opposite the lateral side, the medial side adjacent to the to and bottom sides, wherein a distance between the lateral side and the medial side defines a width, v. a front side adjacent to the top, bottom, lateral, and medial sides, vi. a back side opposite the front side, the back side adjacent to the top, bottom, lateral, and medial sides, wherein a distance between the front side and the back side defines a length, vii. a top edge defined by a junction where the top side meets the front, back, lateral, and medial sides, viii. a bottom edge defined by a junction where the bottom side meets the front, back, lateral, and medial skies; b. a foam core housed inside the shell; c. a skirt attached to a portion of the bottom edge of the shell; d. a handle positioned at a corner; and e. a hinge connecting the first section to the second section at their respective medial sides, wherein each section tapers from the medial side towards the lateral side.
 8. The spa cover of claim 7, wherein the shell comprises a fastener along the medial side and overlapping onto portions of the front and back sides.
 9. The spa cover of claim 7, further comprising a c-channel attached to the medial side of at least one of the sections.
 10. The spa cover of claim 7, wherein the foam core is wrapped and sealed with a barrier.
 11. The spa cover of claim 7, further comprising a gasket attached to the medial side of at least one of the sections.
 12. The spa cover of claim 7, further comprising, an internal handle attached to the medial side of at least one of the sections.
 13. The spa cover of claim 7, wherein the height measured at the medial side is more than two inches higher than the height measured at the lateral side.
 14. A spa cover, comprising a first section and a second section, the first and second sections each comprising: a. as shell having i. a top side, ii. a bottom side opposite the top side, wherein a distance between the top side and the bottom side defines a height, iii. a lateral side adjacent to the top and bottom sides, iv. a medial side opposite the lateral side, the medial side adjacent to the top and bottom sides, wherein a distance between the lateral side and the medial side defines as width, v. a front side adjacent to the top, bottom, lateral, and medial sides, vi. a back side opposite the front side, the back side adjacent to the top, bottom, lateral, and medial sides, wherein a distance between the front side and the back side defines a length, vii. a top edge defined by where the top side meets the front, back, lateral, and medial sides, viii. a bottom edge defined by where the bottom side meets the front, back, lateral, and medial sides Wherein the height at the medial side is more than two inches higher than the height at the lateral side; b. a foam core housed inside the shell; and c. a hinge connecting the first section to the second section at their respective medial sides, wherein each section tapers from the medial side towards the lateral side.
 15. The spa cover of claim 14, wherein the top side comprises a hard plastic.
 16. The spa cover of claim 15, wherein the shell comprises a fastener along the medial side and overlapping onto sides of the front and back sides.
 17. The spa cover of claim 14, wherein the top edge of the shell at any one or more of the from, lateral, and back sides is seamless.
 18. The spa cover of claim 14, wherein the foam core of each section is wrapped and sealed with a barrier.
 19. The spa cover of claim 18, wherein a handle is positioned at an outer corner of at least one section.
 20. The spa cover of claim 19, further comprising a second handle along the medial side of at least one section. 